FoamCore model making Design Build with Foam Board: Wireless Bluetooth Speaker Mock up and  Wahey-C1

FoamCore model making Design Build with Foam Board: Wireless Bluetooth Speaker Mock up and Wahey-C1


You have an idea that you need to bring
to life and you don’t know where to start
well I’m gonna show you how I use foam-core to bring ideas to life my name
is Eric Strebel I’m an industrial designer welcome to my channel about
product design and making I hope that you like and joy and become a subscriber
in my previous videos about foam core we’ll cover some of the basics such as
making a cube how to do that the right way making cylinders soft corners
beveled edges how to cover your foam and not leave any exposed and using foam
core in unconventional ways to create things like compound surfaces in ways
you’ve never thought you could use foam core before all of those techniques are
used in this build you might want to go back and check them out the design for
the speaker is based on a sketch that I did in 2015 I did a video on it it’s not
the greatest sketch that I have ever done and was done on newsprint it was
done pretty quick but I thought it would lend itself to a really nice model and
will allow me to spend some time exploring the proportions and working
out some of the details of that concept so I’m going to start building this
mock-up by building a super structure or a frame that everything is going to be
built around I want to build this frame in such a way that it is adjustable
because I am not 100% sure yet about some of the proportions and I want to
mess around with that and so building a frame that is adjustable allows me to do
that and see I built some simple disks and a rail
system that everything can be adjusted to so once I’m happy with the
proportions I slide it into the right place and I glue everything together
with white glue to let it dry and here’s my finish frame that we’re gonna build
everything on top of to make the pattern for the foam core I’m gonna offset the
surfaces the thickness of the foam and I’m gonna use some white paper and wrap
it around that to make a pattern I’m going to pin them in place and I’m going
to use a pen and mark that and cut out that pattern and that’s gonna be my
pattern for the speakers on the end next we’re gonna attach the screen here
I’ve just used a piece of cardstock like maybe a bristol board and spray-painted
it with a grey primer and that’s going to be the color to represent my screen
in a very simple kind of way I’m just pinning it in place here after I’ve
added some white glue so let’s get back to building the
speaker cones I’m going to take that paper pattern from before I’m going to
trace it onto my foam core and I’m going to cut that shape out next I’m gonna
mark or grid the edges of the foam because we’re going to use some V cuts
here and put that into this curved piece of foam that we have so that we can
actually wrap it around the end of the frame that we’ve made here I’m just
attaching a little bit of white glue all around taping the ends so that when I
get to the other end I can tape it together I put some pins to start to
hold the foam core in place I can easily wrap it around the frame so a lot of
planning went into all of this to make this come out it may take you a couple
of times if you’ve never done this before there will be some trial and
error put the tape on the end to seal it all up looks nice I even get a little
clamp because I want to get the piece of foam halfway on to that disc to be in
the right spot now we’re going to move on to the other end and basically repeat
the process that we did before for the main body we’re gonna cover our foam
core with a piece of packing tape before we start this is going to give us a
glassy surface to simulate a material change next we’re gonna grid up the foam
core I cover this technique extensively in the previous foam core video for
making compound surfaces it’s an offset grid on both sides of the foam core and
allows the foam core to flex and get you compound surfaces the ends of the foam
core need to be curved because it wraps around a cylinder and it has a concave
surface so we’re going to start at the very bottom and we’re just going to pin
that in place and glue it and let that dry before we start to roll
around the forum the next piece up is where the screen goes and I’m cutting
out the screen here very carefully with an exacto knife so we’re gonna butt up
this piece that I just cut out for the screen to the previous piece that’s on
the mock-up already and again go ahead and glue that edge up first I’m going to
let that dry we’re gonna hold that in place with a little bit of tape while
that dries up and that’s gonna give us the best continuous surface from one
piece of foam core to the next I’m gonna wrap that afterwards it’s after it’s
dried and we’re gonna use some rubber bands to sort of hold things in place
we’re gonna repeat this process throughout the entire body this I will
say that this is a pretty unusual build in the sense that you have these
compound services that wrap but it’s an excellent use of this gridded technique
and it works out quite well you’d have a tough time doing this out of any other
sort of sheet material unless you turn something on a lathe we continue to
repeat this process every time the same thing we but up the end piece first let
that dry tape it into place so we get a nice transition from one piece to the
next and then we roll that across the form once it’s dried
each time I’m always using Elmer’s glue or white glue just fine it’s so much
better than hot glue that pulls strings and make a mess yes it takes longer to
dry but your finish in the end is so much nicer and the quality is it’s
totally worth it we only have a few things left to do one of them is to make
the bezel between the screen and the outer body again we’re gonna cover piece
of bristol board here with some clear packing tape to get it shiny so it
matches the texture of the exterior body again gluing stuff in with some PVA
super nice and clean allows me to make adjustments and get the piece just right
I tape everything in with a white artist tape to hold it in place while it dries
once it’s dry I’m just going to come back in with an exacto and I’m gonna
edge trim it just like we’ve done the same in some of the past videos where
we’ve used tape to hide the foam we have one last thing to do and that’s to tape
up the exposed foam on the edge where we put the speakers on in the very
beginning put down some white artists tape and
then come back with my knife and trim it up a mock up like this allows you to
explore proportions and check out scale here it is against my wahi c1 Bluetooth
speaker so you can check it out for size if you’re in the market for like a
budget Bluetooth speaker this wahi c1 is pretty nice it’s pretty thin it’s
circular it’s not the super highest build quality that sound is pretty
decent I like it it’s portable I use it around my studio you can check out the
link below anyway here it is a nice studio shot all
finished mock-up came out nice I like the proportions it was a
worthwhile exercise and definitely something that you want to do when you
do in your product development it’s just a great way to move your product from
one face to the next as you’re doing your design work don’t forget to
subscribe to my youtube channel you can click on a little icon on the bottom
right of the screen to do that so you can follow me on twitter facebook and
through the plus rock on click here to watch some of the other
design I’m making videos that I have if you’d like to have your music featured
in one of my videos drop me a line

11 thoughts on “FoamCore model making Design Build with Foam Board: Wireless Bluetooth Speaker Mock up and Wahey-C1

  1. I wish I had chosen to study for this… Too late now 🙂

    Loved your video series, this one was very educational and exciting.

    /new sub from sweden

  2. As a mechanical designer myself… i wonder why not just print this on a 3D printer? They aren't expensive anymore, and a decent one would print such a model within 3-4 hours. You can go through several iterations with subtle design changes within a week.

  3. Very interesting technique. I've been looking for something like this to finish a big 2,5 feet aircraft model. At the moment it is just a 3D frame but it could very well be filled out in a similar way because the definitive shape is full of compound curves. My question is: Could one further increase the finish of a model such as yours or do you only use this approach as a rough thinking aid.

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